101401-1580 ZEXEL 9 400 613 490 BOSCH INJECTION-PUMP ASSEMBLY 9400613490 1014011580

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 613 490 9400613490

ZEXEL 101401-1580 1014011580

Service parts 101401-1580 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9800

3. GOVERNOR 105921-5710

4. SUPPLY PUMP 105220-6050

5. AUTOM. ADVANCE MECHANIS 105676-0810

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4461

11. Nozzle and Holder ME016315

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3211

14. NOZZLE

105017-0360

15. NOZZLE SET

Include in #1:

101401-1580 as INJECTION-PUMP ASSEMBLY

108622-3456 as _

Cross reference number

BOSCH 9 400 613 490 9400613490

ZEXEL 101401-1580 1014011580

Zexel num

Bosch num

Firm num

Name

101401-1580
101401-1581

9 400 613 490

INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-8720

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 75.5 73.9 77.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 14.8 13.5 16.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 75.5 74.5 76.5

Basic *

Fixing the lever *

Boost pressure kPa 36.7 36.7

Boost pressure mmHg 275 275

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.3

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 96.2 92.2 100.2

Fixing the lever *

Boost pressure kPa 36.7 36.7

Boost pressure mmHg 275 275

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 6)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 47.8 43.8 51.8

Fixing the lever *

Boost pressure kPa 36.7 36.7

Boost pressure mmHg 275 275

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.4

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 33.2 29.2 37.2

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R2-0.4

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2(R1-0. 6)

Boost pressure kPa 23.3 23.3 23.3

Boost pressure mmHg 175 175 175

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=G57 BCL=0.4+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=(38deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)Free (at delivery) (3)Rack position corresponding to bb (4)Set the stopper bolt at speed = cc and rack position = dd (non-injection rack position). Confirm non-injection. (5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less (non-injection rack position).
----------
aa=40mm bb=16mm cc=1700r/min dd=6.6-0.5mm ee=325r/min ff=8mm
----------
a=26.5deg+-5deg b=16deg+-5deg c=33deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=1025r/min Ra=8.5+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11.5deg
----------
a=(130deg)